Structural reinforcement member for a vehicle body

ABSTRACT

A vehicle body includes a structural member having an inner surface defining an elongated cavity. The structural member includes an outer panel member joined to an inner panel member. A reinforcement member is positioned in the cavity wherein a gap is provided between the reinforcement member and the inner surface of the structural member. The reinforcement member includes an outer section, an inner section and a tension web interposed between and contacting the outer section and inner section. The outer section faces the outer panel member and the inner section faces the inner panel member. The tension web is secured to the outer panel member and inner panel member. An adhesive secured to the reinforcement member is activatable to expand toward the inner surface of the structural member to define a joint between the reinforcement member and the structural member and to at least partially fill the gap.

The present application is a continuation of U.S. patent applicationSer. No. 15/668,015, filed Aug. 3, 2017, which claims priority to U.S.patent application Ser. No. 15/019,404, filed Feb. 9, 2016, which claimspriority to U.S. Prov. Patent Appl. Ser. No. 62/114,105, filed Feb. 10,2015, and U.S. Prov. Patent Appl. Ser. No. 62/158,878, filed May 8,2015, the disclosures of each being incorporated herein by reference.

BACKGROUND

The trends in vehicle design are towards lighter vehicles to improvefuel consumption. At the same time, manufacturers continue to demandmore rigorous structural performance standards. The use of lighterhollow cross-sectional structural members that are used to form avehicle body has lead to the need for additional reinforcement membersin various locations in the vehicle body. As is well known, the vehiclebody generally undergoes an electrocoat process in which the vehiclebody is passed through a bath of anticorrosion fluid whereby ananticorrosion coating is deposited onto the vehicle body byelectrolysis. The vehicle body is subsequently heated to bake thecoating on the metal. Therefore, it is desirable that the reinforcementmember does not prevent the provision of the anticorrosion coating onthe inner surface of the hollow member by the electrocoat process.

It is known to provide longitudinal reinforcement members within thehollow structural members of the vehicle body. The reinforcement memberis typically provided with an expandable adhesive on two surfaces, whichcan be foamed upon heating to bond the reinforcement member to twoopposed walls of the structural member. However, this technique is notsuitable for use in the electrocoat process described above as it canprevent the proper electrocoat over the entire inner surface of thestructural member, which can lead to local areas of corrosion. Anotherknown reinforcement member includes a light weight and high strengthaluminum insert. However, it is difficult to isolate the aluminum insertfrom the structural member, which is typically formed of steel or steelalloy, and to correctly position the reinforcement member inside thestructural member. It is also known to provide foamable plastic moldingswithin the structural members which can be foamed upon application ofheat, such as is provided by the baking step in the electrocoat process,to provide a foamed baffle that fills the cross-section to provide soundadsorption. These moldings are generally used to provide acousticbaffles and seals.

BRIEF DESCRIPTION

In accordance with one aspect, a vehicle body comprises a structuralmember having an inner surface defining an elongated cavity. Thestructural member includes an outer panel member joined to an innerpanel member. A reinforcement member is positioned in the cavity of thestructural member wherein a gap is provided between the reinforcementmember and the inner surface of the structural member. The reinforcementmember includes an outer section, an inner section and a tension webinterposed between and contacting the outer section and inner section.The outer section faces the outer panel member and the inner sectionfaces the inner panel member. The tension web is secured to the outerpanel member and inner panel member. An adhesive is secured to thereinforcement member. The adhesive is activatable to expand toward theinner surface of the structural member to define a joint between thereinforcement member and the structural member and to at least partiallyfill the gap.

In accordance with another aspect, a structural reinforcement member fora vehicle body is provided. The vehicle body includes a structuralmember having an inner surface and defining an elongated cavity. Thestructural member includes a first metal or metal alloy. Thereinforcement member is adapted for insertion in the elongated cavitywith a gap between the reinforcement member and the inner surface. Thereinforcement member comprises an outer section, an inner section and atension web interposed between the inner and outer sections. The outersection includes a plurality of laterally extending projections adaptedto be secured to the inner surface of the structural member. The innersection includes a plurality of laterally extending projectionsconfigured to be secured to the tension web. Each of the outer sectionand the inner section includes a reinforced polymer.

In accordance with yet another aspect, a method of reinforcing astructural member of a vehicle body is provided. The structural memberincludes an inner surface defining an elongated cavity, and an outerpanel member joined to an inner panel member. The method comprisesproviding a reinforcement member including an outer section, an innersection and a tension web interposed between and directly secured to theouter and inner sections; providing an adhesive on the reinforcementmember; securing the tension web to the structural member so that thetension web substantially separates the outer and inner panel members;providing a gap between the adhesive and the inner surface of thestructural member prior to activation of the adhesive; and activatingthe adhesive to expand the adhesive outward from the reinforcementmember into engagement with the inner surface of the structural member.

In accordance with yet another aspect, a vehicle body comprises astructural member having an inner surface defining an elongated cavity.The structural member includes an outer panel member joined to an innerpanel member. A reinforcement member is positioned in the cavity of thestructural member wherein a gap is provided between the reinforcementmember and the inner surface of the structural member. The reinforcementmember includes an outer section facing the outer panel member andhaving a closed cross-sectional portion, a separate inner section facingthe inner panel member, and a tension web interposed between andcontacting the outer section and inner section. The tension web issecured to the outer panel member and inner panel member. The closedcross-sectional portion is adapted to increase stiffness and stabilityto the tension web. An adhesive is secured to the reinforcement member.The adhesive is activatable to expand toward the inner surface of thestructural member to define a joint between the reinforcement member andthe structural member and to at least partially fill the gap.

In accordance with yet another aspect, a structural reinforcement memberfor a vehicle body is provided. The vehicle body includes a structuralmember having an inner surface and defining an elongated cavity. Thestructural member includes a first metal or metal alloy. Thereinforcement member is adapted for insertion in the elongated cavitywith a gap between the reinforcement member and the inner surface. Thereinforcement member comprises an outer section, an inner section and atension web interposed between the inner and outer sections. The outersection includes a closed cross-sectional portion having a side wallpart spaced from and substantially parallel to the tension web. Theclosed cross-sectional portion is in direct contact with the tensionweb. The outer section and the tension web include a second metal ormetal alloy different than the first metal or metal alloy. The innersection includes one of the first metal or metal alloy, the second metalor metal alloy, a reinforced polymer, and a honeycomb structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a portion of a vehicle body.

FIG. 2 is a perspective view of an exemplary reinforcement memberaccording to one embodiment of the present disclosure for a structuralmember of the vehicle body portion of FIG. 1.

FIG. 3 is a cross-sectional view of the structural member of the vehiclebody portion of FIG. 1 taken along line A-A of FIG. 1, the structuralmember including the reinforcement member of FIG. 2 prior to attachmentto the structural member.

FIG. 4 depicts the reinforcement member of FIG. 3 fixedly attached tothe structural member.

FIG. 5 is a graph illustrating impact force/displacement of thestructural member including the reinforcement member of FIG. 2 caused bya side impact to the structural member.

FIGS. 6A-6J depict the displacement of the structural member andreinforcement member of FIG. 4 at selected points on the graph of FIG.5.

FIG. 7 is a perspective view of an exemplary reinforcement memberaccording to another embodiment of the present disclosure for thestructural member of the vehicle body portion of FIG. 1.

FIG. 8 is a cross-sectional view of the structural member of the vehiclebody portion of FIG. 1 taken along line A-A of FIG. 1, the structuralmember including the reinforcement member of FIG. 7 prior to attachmentto the structural member.

FIG. 9 depicts the reinforcement member of FIG. 8 fixedly attached tothe structural member.

FIG. 10 is a graph illustrating impact force/displacement of thestructural member including the reinforcement member of FIG. 7 caused bya side impact to the structural member.

FIGS. 11A-11J depict the displacement of the structural member andreinforcement member of FIG. 7 at selected points on the graph of FIG.10.

FIG. 12 is a perspective view of an exemplary reinforcement memberaccording to another embodiment of the present disclosure for thestructural member of the vehicle body portion of FIG. 1.

FIG. 13 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 12 prior toattachment to the structural member.

FIG. 14 depicts the reinforcement member of FIG. 13 fixedly attached tothe structural member.

FIG. 15 is a graph illustrating impact force/displacement of thestructural member including the reinforcement member of FIG. 12 causedby a side impact to the structural member.

FIGS. 16A-16J depict the displacement of the structural member andreinforcement member of FIG. 12 at selected points on the graph of FIG.15.

FIG. 17A is a perspective view of an exemplary reinforcement memberaccording to yet another embodiment of the present disclosure for thestructural member of the vehicle body portion of FIG. 1.

FIGS. 17B and 17C are perspective views of part of the reinforcementmember of FIG. 17A.

FIG. 18 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 17A priorto attachment to the structural member.

FIG. 19 depicts the reinforcement member of FIG. 18 fixedly attached tothe structural member.

FIG. 20 is a graph illustrating impact force/displacement of thestructural member including the reinforcement member of FIG. 17A causedby a side impact to the structural member.

FIGS. 21A-21J depict the displacement of the structural member andreinforcement member of FIG. 17A at selected points on the graph of FIG.20.

FIG. 22 is a perspective view of an exemplary reinforcement memberaccording to a further embodiment of the present disclosure for thestructural member of the vehicle body portion of FIG. 1.

FIG. 23 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 22 prior toattachment to the structural member.

FIG. 24 depicts the reinforcement member of FIG. 23 fixedly attached tothe structural member.

FIG. 25 is a graph illustrating impact force/displacement of thestructural member including the reinforcement member of FIG. 22 causedby a side impact to the structural member.

FIGS. 26A-26J depict the displacement of the structural member andreinforcement member of FIG. 22 at selected points on the graph of FIG.25.

FIG. 27 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including an exemplary reinforcement member accordingto another embodiment of the present disclosure fixedly attached to thestructural member.

FIGS. 28 and 29 are perspective views of a tension web for thereinforcement member of FIG. 27.

FIGS. 30 and 31 are perspective views of an exemplary reinforcementmember according to a further embodiment of the present disclosure forthe structural member of the vehicle body portion of FIG. 1.

FIGS. 32 and 33 are perspective views of an outer section for thereinforcement member of FIGS. 30 and 31.

FIGS. 34 and 35 are perspective views of an inner section for thereinforcement member of FIGS. 30 and 31.

FIG. 36 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 31 prior toattachment to the structural member.

FIGS. 37 and 38 are perspective views of an exemplary reinforcementmember according to a further embodiment of the present disclosure forthe structural member of the vehicle body portion of FIG. 1.

FIGS. 39 and 40 are perspective views of an inner section for thereinforcement member of FIGS. 30 and 31.

FIG. 41 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 38 prior toattachment to the structural member.

FIGS. 42 and 43 are perspective views of an exemplary reinforcementmember according to a further embodiment of the present disclosure forthe structural member of the vehicle body portion of FIG. 1.

FIGS. 44 and 45 are perspective views of an outer section for thereinforcement member of FIGS. 30 and 31.

FIG. 46 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 43 prior toattachment to the structural member.

FIGS. 47 and 48 are perspective views of an exemplary reinforcementmember according to a further embodiment of the present disclosure forthe structural member of the vehicle body portion of FIG. 1.

FIG. 49 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 48 prior toattachment to the structural member.

FIG. 50 is a perspective view of an exemplary reinforcement memberaccording to a further embodiment of the present disclosure for thestructural member of the vehicle body portion of FIG. 1.

FIG. 51 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 50 prior toattachment to the structural member.

FIG. 52 is a perspective view of an exemplary reinforcement memberaccording to a further embodiment of the present disclosure for thestructural member of the vehicle body portion of FIG. 1.

FIG. 53 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 52 prior toattachment to the structural member.

FIGS. 54 and 55 are perspective views of an exemplary reinforcementmember according to a further embodiment of the present disclosure forthe structural member of the vehicle body portion of FIG. 1.

FIGS. 56 and 57 are perspective views of an inner section for thereinforcement member of FIGS. 54 and 55.

FIG. 58 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 55 prior toattachment to the structural member.

FIGS. 59 and 60 are perspective views of an exemplary reinforcementmember according to a further embodiment of the present disclosure forthe structural member of the vehicle body portion of FIG. 1.

FIG. 61 is a cross-sectional view of the structural member of thevehicle body portion of FIG. 1 taken along line A-A of FIG. 1, thestructural member including the reinforcement member of FIG. 60 prior toattachment to the structural member.

DETAILED DESCRIPTION

It should, of course, be understood that the description and drawingsherein are merely illustrative and that various modifications andchanges can be made in the structures disclosed without departing fromthe present disclosure. In general, the figures of the exemplarystructural reinforcement members are not to scale. As used herein, widthor lateral directions are transverse across the vehicle body, i.e., leftand right directions, and the terms inner and outer are relative to thewidth direction of the vehicle body. Likewise, longitudinal directionsrefer to forward and rearward directions of vehicle travel, and thevertical directions relate to elevation, i.e., upward and downwarddirections. It will also be appreciated that the various identifiedcomponents of the exemplary structural reinforcement members disclosedherein are merely terms of art that may vary from one manufacturer toanother and should not be deemed to limit the present disclosure.

Referring now to the drawings, wherein like numerals refer to like partsthroughout the several views, FIG. 1 illustrates a portion of a vehiclebody 100. The portion of the vehicle body 100 is formed of generallyhollow structural members, such as a side sill 102, an A-pillar 104 anda B-pillar 106, that are joined together to define a frame 108. Each ofthe structural members 102, 104, 106 can be reinforced with an exemplarystructural reinforcement member by locating the reinforcement member ina hollow or cavity portion of the structural member as will be describedin greater detail below. The structural reinforcement member can bedisposed along a substantial portion of a longitudinal extent of thestructural member, and is adapted such that when properly positioned inthe structural member, a gap is provided between the reinforcementmember and an inner surface of the structural member. Therefore, theexemplary reinforcement member does not prevent the provision of theanticorrosion coating on the inner surface of the structural member byan electrocoat process.

FIG. 2 depicts an exemplary reinforcement member 120 according to oneembodiment of the present disclosure. The reinforcement member 120incudes an outer section 122, an inner section 124, and a tension web126 interposed between and directly contacting the outer section 122 andthe inner section 124. The outer section 122 of the reinforcement member120 includes a closed cross-sectional portion 130 and first and secondlegs 132, 134 extending outwardly from the closed cross-sectionalportion 130. It should be appreciated that the closed cross-sectionalportion 130 effectively shortens the first and second legs 132, 134,making the first and second legs 132, 134 stiffer in compression. Theclosed cross-sectional portion 130 abuts the tension web 126, and aswill be described below, is adapted to increase stiffness and stabilityof the outwardly extending first and second legs 132, 134 (and, in turn,the tension web 124), particularly during a side or lateral impact tothe structural member. This is advantageous for achieving a preferredforce response curve and deformation mode (see FIG. 5). The innersection 124 of the reinforcement member 120 includes first and secondlegs 140, 142 in contact with and extending outwardly from the tensionweb 126.

In the depicted embodiment of the reinforcement member 120, the closedcross-sectional portion 130 is triangular shaped and is at leastpartially defined by respective end portions 146, 148 of the first andsecond legs 132, 134. The end portions 146, 148 converge toward oneanother and intersect to define an apex or node 150 of the closedcross-sectional portion 130. Stability of the reinforcement member 120is achieved though having the first and second legs 132, 134 converge onthe node 150. A separate wall part 152 of the closed cross-sectionalportion 130 is spaced from and extends substantially parallel to thetension web 126. It should be appreciated that the closedcross-sectional portion 130 can have alternative polygonal shapes and isnot limited to the depicted shape. The first and second legs 140, 142 ofthe inner section 124 converge toward and intersect at the node 150. Atleast one of the first and second legs 140, 142 of the inner section 124has a kink or bend which moves the one leg slightly toward the otherleg. The kink is provided to control deformation of that leg during aside or lateral impact to the structural member. According to oneaspect, the first leg 140 includes an upward kink 156 locatedsubstantially centrally on the first leg 140. According to anotheraspect, the second leg 142 includes a downward kink 158 locatedsubstantially centrally on the second leg 142. As will be described indetail below, the kink or bend 156, 158 in each of the respective firstand second legs 140, 142 are adapted to allow a portion each leg to foldat least partially into the tension web 126 during a side impact to thestructured member.

FIGS. 3 and 4 depict the structural member or side sill 102 having theexemplary reinforcement member 120 located therein. The structuralmember or side sill 102 can be formed of an outer panel member 160joined to an inner panel member 162, inner surfaces of the inner andouter panel members 160, 162 defining an elongated cavity 166. The outerpanel member 160 can be hat-shaped in cross-section and includes a baseor side wall 170, a top wall 172 and a bottom wall 174. A flange 176extends outwardly from an end portion of the top wall 172 and a flange178 extends outwardly from an end portion of the bottom wall 174.Similarly, the inner panel member 162 can be hat-shaped in cross-sectionand includes a base or side wall 180, a top wall 182, and a bottom wall184. The top wall 182 and bottom wall 184 can each include a kink orbend allowing a portion each wall 182, 184 to fold during a side impactto the structured member 102. A flange 186 extends outwardly from an endportion of the top wall 182, and a flange 188 extends outwardly from anend portion of the bottom wall 184. The flanges 176, 178 of the outerpanel member 160 are fixedly attached (e.g., by welding) to thecorresponding flanges 186, 188 of the inner panel member 162.

The structural member or side sill 102, which can be a stamped member,includes a first metal or a metal alloy, and can be formed of a steel orsteel alloy. The outer section 122 of the exemplary reinforcement member120 includes a second metal or metal alloy different from the firstmetal or metal alloy, and can be formed of an aluminum or aluminumalloy. According to one aspect, the tension web 126 is also formed ofthe second metal or metal alloy. As depicted in FIGS. 3 and 4, thetension web 126 is secured to the outer and inner panel members 160, 162of the structural member or side sill 102. To prevent the occurrence ofgalvanic corrosion between the differing materials of the tension web126 and the structural member 102, a separate segment member 190 formedof the first metal or metal alloy is provided at an upper portion 192 ofthe tension web 126. The segment member 190 is adapted to connect theupper flanges 176, 186 of the outer and inner panel members to the upperportion of the tension web 126. A lower portion 194 of the tension web126 is provided with a joining part 198 formed of the first metal ormetal alloy. According to one aspect, the joining part 198 can be a slugof the first metal or metal alloy provided formed in the lower portion194. According to another aspect, the joining part 198 can be a separatesegment member similar to segment member 190. The joining part 198 isadapted to connect the lower flanges 178, 188 of the outer and innerpanel members 160, 162 to the lower portion of the tension web 126. Theinner section 124 of the exemplary reinforcement member 120 can includethe second metal or metal alloy. This allows the reinforcement member120 to be integrally formed as a one-piece, unitary member, such as byan extrusion process.

As shown in FIGS. 3 and 4, the reinforcement member 120 is positioned inthe cavity 166 of the structural member 102 wherein a gap 200 isprovided between the reinforcement member 120 and the inner surfaces ofthe outer and inner panel members 160, 162. The outer section 122 facesthe outer panel member 160 with the first and second legs 132, 134extending toward the inner surface of the outer panel member 160, andthe inner section 124 faces the inner panel member 162 with the firstand second legs 142, 144 extending toward the inner surface of the innerpanel member 162. End portions 210, 212 of the respective first andsecond legs 132, 134 of the outer section 122 (which are opposite endportions 146, 148) are provided with flanges 216, 218 shaped to conformto respective upper and lower corner portions 220, 222 of the outerpanel member 160. Similarly, end portions 230, 232 of the respectivefirst and second legs 142, 144 of the inner section 124 are providedwith flanges 236, 238 shaped to conform to respective upper and lowercorner portions 240, 242 of the inner panel member 162.

An adhesive 246, which can be structural foam, is secured to thereinforcement member 120. In the depicted embodiment, the adhesive issecured to each of the flanges 216, 216 of the outer section 122 andeach of the flanges 236, 238 of the inner section 124. The adhesive 246is selected so as to be activatable under a desired condition. Usedherein, activatable means that the adhesive 246 softens (e.g., melts),cures, expands, foams or a combination thereof upon exposure to acondition. Thus, according to one embodiment, the adhesive 246 may be aheat-activated and/or epoxy-based resin having foamable characteristics.Of course, the adhesive 246 may be activated by other conditions orstimuli. The choice of the adhesive 246 used will typically be dictatedby performance requirements and economics of the specific applicationand requirements. The gap 200 provided between the adhesive 246 and theinner surfaces of the outer panel member 160 and inner panel member 162allows anticorrosion fluid to flow between the reinforcement member 120and the inner surface of the structural member 102. According to thepresent disclosure, the adhesive is substantially dry to the touch priorto activation and is activatable to expand toward the inner surface ofthe side sill 102 to fill at least a portion of the gap 200 when thevehicle body 100 is sent through a paint process and the adhesive isexposed to increased temperatures. The adhesive 246 also has increasedductility for better load distribution along the entire longitudinalaxis of the reinforcement member 120. To secure the adhesive 246 to thereinforcement member 120, the adhesive can be preheated to a temperaturesuitable to make it tacky, yet low enough that it will not exceed itscure or expansion temperature.

To secure the exemplary structural reinforcement member 120 within thecavity 166 of the structural member 102, the segment member 190 isattached to the upper portion 192 of the tension web 126. It should beappreciated that the segment member 190 can be attached to the upperportion 192 by conventional fasteners, such as self-piercing rivets, anda separate adhesive/insulator 250 can be placed between the tension web126 and segment member 190 to prevent galvanic corrosion. The segmentmember 190 is interposed between and is directly secured (e.g., bywelding) to the upper flanges 176, 186 of the outer and inner panelmembers 160, 162. The lower portion 194 of the tension web is interposedbetween the lower flanges 178, 188 of the outer and inner panel members160, 162. Again, an adhesive/insulator 252 can be placed between thetension web 126 and lower flanges 178, 188 to prevent galvaniccorrosion. The joining part 198 is directly secured (e.g., by welding)to the lower flanges 178, 188 of the outer and inner panel members 160,162.

FIG. 5 graphically depicts an impact or test barrier force versesdisplacement caused by a side impact to the structural member or sidesill 102 having the reinforcement member 102 positioned in the cavity166 of the structural member. FIGS. 6A-6J schematically depict, incross-section, the deformation of the structural member 102 andreinforcement member 120 at selected points on the graph of FIG. 5. Itshould be appreciated from the description below that the first andsecond legs 132, 134 of the outer section 122 and the first and secondlegs 140, 142 of the inner section 124 define a lateral load pathbetween the outer and inner panel members 160, 162 during a side impactto the structural member 102.

In FIG. 6A, initial force from a side impact to the outer panel member160 of the structural member 102 causes partial deformation of the sidewall 170 and the first leg 132 of the outer section 122. The end portion210 of the first leg 132 begins to kink or bend at point 01 due todeformation of the joint defined by the flange 216 adhered to the uppercorner portion 220. FIG. 6B shows the first leg 132 continuing to kinkor bend at point 02, wherein a section 260 of the first leg 132 locatedbetween the end portions 146, 210 begins to fold upwardly in the vehiclebody height direction toward the tension web 126 generally about theintersection between the wall part 152 of the closed cross-sectionalportion 130 and the end portion 146 of the first leg 132 (which at leastpartially defines the closed cross-sectional portion 130). The endportion 212 of the second leg 134 also begins to kink or bend caused bydeformation of the joint defined by the flange 218 adhered to the lowercorner portion 222. It should also be appreciated that the lateral loadpath of each of the first and second legs 132, 134 is directed thoughthe node 150 to the first and second legs 140, 142 of the inner section124. This, in turn, causes each of the first and second legs 140, 142 tostart to deform at their respective kinks 156, 158 due to the jointsdefined by the respective flanges 236, 238 adhered to the upper andlower corner portions 240, 242.

In FIG. 6C, the lateral load continues to fold the first leg 132 atpoint 03, and the section 260 of the first leg 132 is movedsubstantially parallel to the tension web 126. Further, a section 262 ofthe second leg 134 located between the end portions 148, 212 foldsdownwardly in the vehicle body height direction toward the tension web126 generally about the intersection between the wall part 152 of theclosed cross-sectional portion 130 and the end portion 148 of the secondleg 134 (which at least partially defines the closed cross-sectionalportion 130). FIG. 6D depicts the section 260 of the first leg 132bended more toward the tension web 126 and the section 262 of the secondleg 134 substantially parallel to the tension web 126. The closedcross-sectional portion 130 begins to partially deform and the first leg140 of the inner section 124 continues to deform about the kink 156 (seepoint 04). Further, the continued lateral force applied to the outerpanel member 160 starts to deform the tension web 126.

FIGS. 6E and 6F depict each of the sections 260, 262 of the respectivefirst and second legs 132, 134 of the outer section 122 folded moretoward the tension web 126. With continued lateral force applied to thestructural member 102, the kink or bend 156, 158 in each of the firstand second legs 140, 142 of the inner section 124 is adapted to allow asection each leg 140, 142 to fold at least partially into the tensionweb 126 (see points 05 and 06). Particularly, the first leg 140 isadapted to fold upwardly in the vehicle body height direction such thata section 270 of the first leg 140 located between the node 150 and thekink 156 is substantially parallel to the tension web 126, and a section272 of the first leg 140 located between the kink 156 and the endportion 230 is substantially perpendicular to the tension web 126. Thesecond leg 142 is also adapted to fold upwardly in the vehicle bodyheight direction (because kink 158 is moving upwardly relative to itsoriginal position) such that a section 274 of the second leg 142 locatedbetween the node 150 and the kink 158 is substantially perpendicular tothe tension web 126, and a section 276 of the second leg 142 locatedbetween the kink 158 and the end portion 232 is substantially parallelto the tension web 126.

As illustrated in FIGS. 6G and 6H, the closed cross-sectional portion130 of the outer section 122 continues to deform from the lateral forceapplied to the structural member 120. And the first and second legs 140,142 of the inner section 124 continue to fold about their respectivekinks 156, 158 (see point 07). The section 270 of the first leg 140 ismoved into engagement with the tension web 126, and the kink 158 of thesecond leg 142 moves upward in the vehicle body height direction (seepoint 08). FIG. 6I depicts the first and second legs 132, 134 of theouter section 122 in direct contact with the tension web 126. The firstleg 140 of the inner section 124 is further folded upwards such that apart of the section 272 of the first leg 140 is in contact with thetension web 126. The kink 158 of the second leg of the inner section 124engages the side wall 180 of the inner panel member 162 (see point 09).FIG. 6J depicts a final deformed state of the structural member 102 andreinforcement member 120 at point 10 on the graph of FIG. 5.

FIG. 7 depicts an exemplary reinforcement member 300 according toanother embodiment of the present disclosure. The reinforcement member300 incudes an outer section 302, an inner section 304, and a tensionweb 306 interposed between and directly contacting the outer section 302and the inner section 304. The outer section 302 of the reinforcementmember 300 includes a closed cross-sectional portion 310 and first andsecond legs 312, 314 extending outwardly from the closed cross-sectionalportion 310. Similar to the reinforcement member 120, the closedcross-sectional portion 310 effectively shortens the first and secondlegs 312, 314, making the first and second legs stiffer in compression.The closed cross-sectional portion 310 abuts the tension web 306 and isadapted to increase stiffness and stability of the first and second legs312, 314 (and, in turn, the tension web 306), particularly during a sideor lateral impact to the structural member. The inner section 304 of thereinforcement member 300 is generally hat-shaped and includes first andsecond legs 320, 322 extending outwardly from a base member 324 incontact with the tension web 306.

The closed cross-sectional portion 310 is rectangular shaped and is atleast partially defined by respective end portions 326, 328 of the firstand second legs 312, 314. It should be appreciated that due to thesingle node 150 of the reinforcement member 120 being effectivelyreplaced by two nodes in this embodiment (the two nodes defined by theintersection of each end portion 326, 328 and the tension web 306), thetension web 306 is enhanced compared to the tension web 126. The endportions 326, 328 define substantially horizontal wall parts of theclosed cross-sectional portion 310. As best shown in FIGS. 8 and 9, thesubstantially horizontal wall parts 326, 328 of the closedcross-sectional portion 310 are at least partially curved toward oneanother, and are adapted to at least partially collapse into an enclosedspace 330 defined by the cross-sectional portion 310. A separate wallpart 336 of the closed cross-sectional portion 310 is spaced from andextends substantially parallel to the tension web 306. The base member324 of the inner section 304 is secured to the tension web 306 at thesame location on the tension web as the closed cross-sectional portion310.

As indicated previously, the structural member or side sill 102 includesa first metal or a metal alloy, and can be formed of a steel or steelalloy. The outer section 302 of the exemplary reinforcement member 300includes a second metal or metal alloy different from the first metal ormetal alloy, and can be formed of an aluminum or aluminum alloy.According to one aspect, the tension web 306 is also formed of thesecond metal or metal alloy. This allows the outer section 302 andtension web 306 to be integrally formed as a one-piece, unitary member,such as by an extrusion process. In contrast to the reinforcement member120, the inner section 304 of the exemplary reinforcement member 300 caninclude the first metal or metal alloy. It should be appreciated thatthe inner section 304 can be attached to the tension web 306 byconventional fasteners, such as self-piercing rivets, and anadhesive/insulator 340 can be placed between the tension web 306 andbase member 324 to prevent galvanic corrosion (see FIG. 8). As depictedin FIGS. 8 and 9, the tension web 306 is secured to the outer and innerpanel members 160, 162 of the structural member or side sill 102 in thesame manner as the tension web 126 (e.g., by use of the separate segmentmember 190 and joining part 198). Accordingly, further discussion of theconnection of the reinforcement member 300 within the cavity 166 of thestructural member 102 will be omitted for conciseness.

As shown in FIGS. 8 and 9, and similar to the previous embodiment, thereinforcement member 300 is positioned in the cavity 166 of thestructural member 102 such that a gap 350 is initially provided betweenthe reinforcement member 300 and the inner surfaces of the outer andinner panel members 160, 162. As indicated previously, the gap 350allows for the provision of the anticorrosion coating on the innersurface of the structural member by an electrocoat process. The outersection 302 faces the outer panel member 160 with the first and secondlegs 312, 314 extending toward the inner surface of the outer panelmember 160, and the inner section 304 faces the inner panel member 162with the first and second legs 320, 322 extending toward the innersurface of the inner panel member 162. End portions 356, 358 of therespective first and second legs 312, 314 of the outer section 302(which are opposite end portions 326, 328) are provided with flanges364, 366 shaped to conform to the respective upper and lower cornerportions 220, 222 of the outer panel member 160. Similarly, end portions368, 370 of the respective first and second legs 320, 322 of the innersection 304 are provided with flanges 374, 376 shaped to conform to therespective upper and lower corner portions 240, 242 of the inner panelmember 162. In the depicted embodiment, the adhesive 246 is secured toeach of the flanges 364, 366 of the outer section 302 and each of theflanges 374, 376 of the inner section 304. The adhesive 246 attaches theflanges 364, 366 to the respective upper and lower corner portions 220,222 of the outer panel member 160 and attaches the flanges 374, 376 tothe respective upper and lower corner portions 240, 242 of the innerpanel member 162.

FIG. 10 graphically depicts an impact or test barrier force versesdisplacement caused by a side impact to the structural member or sidesill 102 having the reinforcement member 300 positioned in the cavity166 of the structural member. FIGS. 11A-11J schematically depict, incross-section, the deformation of the structural member 102 andreinforcement member 300 at selected points on the graph of FIG. 10.Similar to the previous embodiment of the reinforcement member, thefirst and second legs 312, 314 of the outer section 302 and the firstand second legs 320, 322 of the inner section 304 of the exemplaryreinforcement member 300 define a lateral load path from the outer panelmember 160 toward the inner panel member 162 during a side impact to thestructural member 102.

In FIG. 11A, initial force from a side impact to the outer panel member160 of the structural member 102 causes partial deformation of the sidewall 170 and the first and second legs 312, 314 of the outer section302. The end portion 356 of the first leg 312 begins to kink or bend atpoint 01 due to deformation of the joint defined by the flange 364adhered to the upper corner portion 220. FIG. 11B shows the first leg312 continuing to kink or bend at point 02, wherein a section 380 of thefirst leg 312 located between the end portions 326, 356 begins to foldupwardly in the vehicle body height direction toward the tension web 306generally about the intersection between the wall part 336 of the closedcross-sectional portion 310 and the end portion 326 of the first leg 312(which defines a substantially horizontal wall part of the closedcross-sectional portion 310). The end portion 358 of the second leg 314also begins to kink or bend caused by deformation of the joint definedby the flange 366 adhesively adhered to the lower corner portion 222. Itshould be appreciated that the lateral load path of each of the firstand second legs 312, 314 is directed though the closed cross-sectionalportion 310 and the tension web 306 to the inner section 304.

In FIG. 11C, the lateral load continues to fold the first leg 312 of theouter section 302 at point 03, and the section 380 of the first leg 312is moved substantially parallel to the tension web 306. Further, asection 382 of the second leg 314 located between the end portions 328,358 folds downwardly in the vehicle body height direction toward thetension web 306 (see point 03) generally about the intersection betweenthe wall part 336 of the closed cross-sectional portion 310 and the endportion 328 of the second leg 314 (which defines a substantiallyhorizontal wall part of the closed cross-sectional portion 310). FIG.11D depicts the section 380 of the first leg 312 bended more toward thetension web 306 and the section 382 of the second leg 314 substantiallyparallel to the tension web 306. The closed cross-sectional portion 310begins to partially deform (see point 04). As depicted, the end portions326, 328 (i.e., the substantially horizontal wall parts of the closedcross-sectional portion 310) begin to at least partially collapse intothe enclosed space 330 defined by the closed cross-sectional portion.The wall part 336 bulges toward the side wall 170 of the outer panelmember 160. And the closed cross-sectional portion 310 at leastpartially forces the base member 324 of the inner section 304 toward theside wall 180 of the inner panel member 162. This, in turn, causes eachof the first and second legs 320, 322 to deform due to the jointsdefined by the respective flanges 374, 376 adhered to the upper andlower corner portions 240, 242. Further, the continued lateral forceapplied to the outer panel member 160 starts to deform the tension web306.

FIGS. 11E and 11F depict each of the sections 380, 382 of the respectivefirst and second legs 312, 314 of the outer section 302 folded moretoward the tension web 306. The wall part 336 of the closedcross-sectional portion 310 is moved into contact with the side wall 170of the outer panel member 160, and the end portions 326, 328 arecollapsed further toward one another. The tension web 306 in the area ofthe closed cross-sectional portion 310 bulges more toward the side wall180 of the inner panel member 162 (see points 05 and 06). The continuedlateral force applied to the structural member 102 further causes endportions 386, 388 of the first and second legs 320, 322 to fold alongthe tension web 306 (which increases the stiffness and energy absorbingcharacteristics of the tension web 306) and the end portions 368, 370 ofthe first and second legs 320, 322 to fold along the side wall 180 (seepoints 05 and 06).

As illustrated in FIGS. 11G and 11H, the closed cross-sectional portion310 of the outer section 302 continues to deform from the lateral forceapplied to the structural member 120. And the first and second legs 320,322 of the inner section 304 continue to fold along the tension web 306and the side wall 180 of the inner panel member 162 (see point 07). Thetension web 306 bulges further toward the side wall 180 particularly atthe intersection of the end portion 326 of the first leg 312 of theouter section 302 and the tension web 306 (see point 08). Further, atpoint 08 the first leg 320 of the inner section 304 begins to kink orbend near the end portion 368. FIG. 111 depicts the first and secondlegs 320, 322 of the inner section 304 further deformed (see point 09).FIG. 11J depicts a final deformed state of the structural member 102 andreinforcement member 300 at point 10 on the graph of FIG. 10.

FIG. 12 depicts an exemplary reinforcement member 400 according toanother embodiment of the present disclosure. The reinforcement member400 incudes an outer section 402, an inner section 404, and a tensionweb 406 interposed between and directly contacting the outer section 402and the inner section 404. The outer section 402 is structurally similarto the outer section 302 of the reinforcement member 300. Therefore,similar components are identified with like reference numerals, but withthe integer “4” (e.g., closed cross-sectional portion 310 is referencedas 410). Like the outer section 302, the outer section 402 includes aclosed cross-sectional portion 410 and first and second legs 412, 414extending outwardly from the closed cross-sectional portion 410. Endportions 426, 428 of the respective first and second legs 412, 414define substantially horizontal wall parts of the closed cross-sectionalportion 410. Again, the end portions 426, 428 are curved toward oneanother and are adapted to at least partially collapse into the closedcross-sectional portion during a side impact to the structural member102. Wall part 436 of the closed cross-sectional portion 410 is spacedfrom and extends substantially parallel to the tension web 406. Flanges464, 466 located on end portions 456, 458 of the respective first andsecond legs 412, 414 have placed thereon the adhesive 246.

The inner section 404 of the reinforcement member 400 is a honeycombstructure 480 defining a plurality of openings or cells which areoriented substantially normal to a longitudinal axis defined by thestructural member 102. The honeycomb structure 480 is adhered to thetension web 406 via the adhesive 246, and can have a shape thatsubstantially conforms to a cross-section of a section of the structuralmember 102 to be reinforced by the honeycomb structure. It should beappreciated that the size of the openings or cells of the honeycombstructure can be dimensioned to suite the specific design requirementsof the reinforcement member 400 and structural member 102, the smallerthe cell size the increased stiffness of the honeycomb structure 480.The adhesive 246 is provided on opposite side surfaces 482, 484 of thehoneycomb structure 480, which positions the adhesive 426 on oppositesides of the openings of the honeycomb structure 480.

As indicated previously, the structural member or side sill 102 includesa first metal or a metal alloy, and can be formed of a steel or steelalloy. The outer section 402 of the exemplary reinforcement member 400includes a second metal or metal alloy different from the first metal ormetal alloy, and can be formed of an aluminum or aluminum alloy. Thetension web 406 can also formed of the second metal or metal alloy,which allows the outer section 402 and tension web 406 to be integrallyformed as a one-piece, unitary member, such as by an extrusion process.According to one aspect, the honeycomb structure 480 of the innersection 404 can include the second metal or metal alloy; although, thisis not required.

As depicted in FIGS. 13 and 14, the tension web 406 is secured to theouter and inner panel members 160, 162 of the structural member or sidesill 102 in the same manner as the tension webs 126, 306 (e.g., by useof the separate segment member 190 and joining part 198). Accordingly,further discussion of the connection of the reinforcement member 400within the cavity 166 of the structural member 102 will also be omittedfor conciseness. As shown in FIG. 13, the reinforcement member 400 isinitially positioned in the cavity 166 of the structural member 102 suchthat a gap 490 is provided between the reinforcement member 400 and theinner surfaces of the outer and inner panel members 160, 162. Again, thegap 490 allows for the provision of the anticorrosion coating on theinner surface of the structural member by an electrocoat process. Theouter section 402 faces the outer panel member 160 with the first andsecond legs 412, 414 extending toward the inner surface of the outerpanel member 160, and the inner section 404 faces the inner panel member162. The honeycomb structure 480 is adhered to the tension web 406beneath the segment member 190.

FIG. 15 graphically depicts an impact or test barrier force versesdisplacement caused by a side impact to the structural member or sidesill 102 having the reinforcement member 400 positioned in the cavity166 of the structural member. FIGS. 11A-11J schematically depict, incross-section, the deformation of the structural member 102 andreinforcement member 400 at selected points on the graph of FIG. 15.Similar to the previous embodiments of the reinforcement member, thefirst and second legs 412, 414 of the outer section 402 together withthe honeycomb structure 480 define a lateral load path from the outerpanel member 160 to the inner panel member 162 during a side impact tothe structural member 102.

In FIG. 16A, initial force from a side impact to the outer panel member160 of the structural member 102 causes partial deformation of the sidewall 170 and the first and second legs 412, 414 of the outer section402. The end portion 456 of the first leg 412 begins to kink or bend atpoint 01 due to deformation of the joint defined by the flange 464adhered to the upper corner portion 220. FIG. 16B shows the first leg412 continuing to kink or bend at point 02, wherein a section 492 of thefirst leg 412 located between the end portions 426, 456 begins to foldupwardly in the vehicle body height direction toward the tension web 406generally about the intersection between the wall part 436 of the closedcross-sectional portion 410 and the end portion 426 of the first leg412. The end portion 458 of the second leg 414 also begins to kink orbend caused by deformation of the joint defined by the flange 466adhered to the lower corner portion 222.

In FIG. 16C, the lateral load continues to fold the first leg 412 of theouter section 402 at point 03, and the section 492 of the first leg 412is moved substantially parallel to the tension web 406. Further, asection 494 of the second leg 414 located between the end portions 428,458 starts to fold downwardly in the vehicle body height directiontoward the tension web 306 (see point 03) generally about theintersection between the wall part 436 of the closed cross-sectionalportion 410 and the end portion 428 of the second leg 414. FIG. 16Ddepicts the section 492 of the first leg 412 and the section 494 of thesecond leg 414 bended more toward the tension web 406 (see point 04).The closed cross-sectional portion 410 presses against tension web 406causing the tension web to at least partially bulge toward the side wall180 of the inner panel member 162. This, in turn, causes partial bulgingof the honeycomb structure 480 and the side wall 180. As depicted, theend portions 426, 428 (i.e., the substantially horizontal wall parts ofthe closed cross-sectional portion 410) also begin to at least partiallycollapse into the enclosed space 430 defined by the closedcross-sectional portion 410.

FIG. 16E depicts each of the sections 492, 494 of the respective firstand second legs 412, 414 of the outer section 402 folded more toward thetension web 406, wherein each of the sections 492, 494 are orientedsubstantially parallel to the tension web 406 (see point 05). Thetension web 406 and the honeycomb structure 480 are deformed more towardthe side wall 180 of the inner panel member 162. In FIG. 16E, the wallpart 436 of the closed cross-sectional portion 410 is in contact withthe side wall 170 of the outer panel member 160, and the end portions426, 428 are collapsed further toward one another. The tension web 406in the area of the closed cross-sectional portion 410 bulges more towardthe side wall 180 of the inner panel member 162 (see point 06). Thecontinued lateral force applied to the structural member 102 furtherbulges the side wall 180 via the honeycomb structure 480. Further, thebottom wall 184 of the inner panel member protrudes into the honeycombstructure 480.

As illustrated in FIGS. 16G and 16H, the closed cross-sectional portion410 of the outer section 402 continues to deform from the lateral forceapplied to the structural member 120. And the tension web 406 andhoneycomb structure 480 deform further toward the side wall 180 of theinner panel member 162 (see points 07 and 08). FIG. 16I depicts thefirst and second legs 412, 414 and the closed cross-sectional portion410 of the outer section 402 further deformed (see point 09). FIG. 16Jdepicts a final deformed state of the structural member 102 andreinforcement member 400 at point 10 on the graph of FIG. 15.

FIGS. 17A-17C depict an exemplary reinforcement member 500 according toanother embodiment of the present disclosure. The reinforcement member500 includes an outer section 502, an inner section 504, and a tensionweb 506 interposed between and directly contacting the outer section 502and the inner section 504. The outer section 502 is structurally similarto the outer sections 302, 402 of the reinforcement members 300, 400.Therefore, similar components are identified with like referencenumerals, but with the integer “5” (e.g., closed cross-sectional portion310, 410 is referenced as 510). Like the outer sections 302, 402, theouter section 502 includes a closed cross-sectional portion 510 andfirst and second legs 512, 514 extending outwardly from the closedcross-sectional portion 510. End portions 526, 528 of the respectivefirst and second legs 512, 514 define substantially horizontal wallparts of the closed cross-sectional portion 510. Again, the end portions526, 528 are curved toward one another and are adapted to at leastpartially collapse into the closed cross-sectional portion during a sideimpact to the structural member 102. Wall part 536 of the closedcross-sectional portion 510 is spaced from and extends substantiallyparallel to the tension web 506. Flanges 564, 566 located on endportions 556, 558 of the respective first and second legs 512, 514 haveplaced thereon the adhesive 246. The adhesive 246 attaches the flanges564, 566 to the respective upper and lower corner portions 220, 222 ofthe outer panel member 160.

The inner section 504 includes a base member 570 having an upper firstleg 572 and a lower second leg 574. The base member 570 is adhered tothe tension web 506 via the adhesive 246. It should be appreciated thatthe base member 570 can also be attached to the tension web 506 byconventional fasteners, such as clips or rivets. The first leg 572,which can extend continuously without interruption along thelongitudinal extent of the base member 570, extends upwardly andoutwardly from the base member. Similarly, the second leg 574, which canalso extend continuously without interruption along the longitudinalextent of the base member 570, extends downwardly and outwardly from thebase member. A distal end portion 576 of the first leg 572 has a shapecomplimentary to the upper corner portion 240 of the inner panel member162. And a distal end portion 578 of the second leg 574 has a shapecomplimentary to the lower corner portion 242 of the inner panel member162. The adhesive 246 is provided on each end portion 576, 578, whichattaches the end portions to the respective upper and lower cornerportions 240, 242 of the inner panel member 162.

According to one aspect, a plurality of spaced apart first reinforcingribs 580 can be provided on an outer surface 582 of the first leg 572along the elongated length of the first leg 572. And a plurality ofspaced apart second reinforcing ribs 584 can be provided an outersurface 586 of the second leg 582 along the elongated length of thesecond leg 574. According to another aspect, located between each pairof adjacent first reinforcing ribs 580 is a first cutout 590, andlocated between each pair of adjacent second reinforcing ribs 584 is asecond cutout 592. The first and second cutouts 590, 592 can reduce theoverall weight of the inner section 504. In the depicted exemplaryembodiment, a plurality of generally X-shaped third reinforcing ribs 596can extend between an inner surface 600 of the first leg 572 and aninner surface 602 of the second leg 574. Upper end portions 604, 606 ofeach third reinforcing rib 596 flank one of the first cutouts 590, andlower end portions 608, 610 of each third reinforcing rib 596 flank oneof the second cutouts 592. The inner section 504 can further includeopposite end supports 614, 616.

The inner section 504 of the exemplary reinforcement member 500 is aone-piece, unitary member formed of a reinforced polymer. In oneembodiment, the inner section 504 is formed from a fiber reinforcedplastic including a plastic matrix material that encapsulates a fibermaterial. For example, the plastic matrix material can be nylon and/orthe fiber material can be a plurality of glass fibers, which providespreferred structural characteristics while maintaining a reasonableweight for the inner section 504.

As depicted in FIGS. 18 and 19, the tension web 506 is secured to theouter and inner panel members 160, 162 of the structural member or sidesill 102 in the same manner as the tension webs 126, 306, 406 (e.g., byuse of the separate segment member 190 and joining part 198).Accordingly, further discussion of the connection of the reinforcementmember 500 within the cavity 166 of the structural member 102 will alsobe omitted for conciseness. As shown in FIG. 18, the reinforcementmember 500 is initially positioned in the structural member 102 suchthat a gap 620 is provided between the reinforcement member 500 and theinner surfaces of the outer and inner panel members 160, 162. Again, thegap 620 allows for the provision of the anticorrosion coating on theinner surface of the structural member by an electrocoat process. Theouter section 502 faces the outer panel member 160 with the first andsecond legs 512, 514 extending toward the inner surface of the outerpanel member 160, and the inner section 504 faces the inner panel member162 with the first and second legs 572, 574 extending toward the innersurface of the inner panel member 162. As best depicted in FIGS. 18 and19, a kink or bend 622 is provided in the first leg 572 adjacent thefirst reinforcing ribs 580, and a kink or bend 624 is provided in thesecond leg 574 adjacent the second reinforcing ribs 582. It should beappreciated that the kinks 622, 624 in the respective first and secondlegs 572, 574 are adapted to tune or control deformation and bending ofthe inner section 504 to prevent breakage of the inner section 504during a side impact to the structural member 102.

FIG. 20 graphically depicts an impact or test barrier force versesdisplacement caused by a side impact to the structural member or sidesill 102 having the reinforcement member 500 positioned in the cavity166 of the structural member. FIGS. 21A-21J schematically depict, incross-section, the deformation of the structural member 102 andreinforcement member 500 at selected points on the graph of FIG. 20.Similar to the previous embodiments of the reinforcement member, thefirst and second legs 512, 514 of the outer section 502 together withthe first and second legs 572, 574 of the inner section 504 define alateral load path from the outer panel member 160 to the inner panelmember 162 during a side impact to the structural member 102.

In FIG. 21A, initial force from a side impact to the outer panel member160 of the structural member 102 causes partial deformation of the sidewall 170 and the first and second legs 512, 514 of the outer section502. The end portion 556 of the first leg 512 begins to kink or bend atpoint 01 due to deformation of the joint defined by the flange 564adhered to the upper corner portion 220. FIG. 21B shows the first leg512 continuing to kink or bend, wherein a section 630 of the first leg512 located between the end portions 526, 556 begins to fold upwardly inthe vehicle body height direction toward the tension web 506 generallyabout the intersection between the wall part 536 of the closedcross-sectional portion 510 and the end portion 526 of the first leg 512(which defines a substantially horizontal wall part of the closedcross-sectional portion 510). Lateral load is also being transferred tothe tension web 506 at point 02 causing slight deformation of thetension web 506.

In FIG. 21C, the lateral load continues to fold the first leg 512 of theouter section 502 at point 03, and the section 630 of the first leg 512is moved substantially parallel to the tension web 506. The end portion558 of the second leg 514 also begins to kink or bend at point 03 causedby deformation of the joint defined by the flange 566 adhered to thelower corner portion 222. Further, a section 632 of the second leg 514located between the end portions 528, 558 folds downwardly in thevehicle body height direction toward the tension web 506 (see point 03)generally about the intersection between the wall part 536 of the closedcross-sectional portion 510 and the end portion 528 of the second leg514 (which defines a substantially horizontal wall part of the closedcross-sectional portion 510). It should be appreciated that the lateralload path of each of the first and second legs 512, 514 is directedthough the closed cross-sectional portion 510 and the tension web 506 tothe inner section 504. The tension web 506 begins to bulge toward theside wall 180 of the inner panel member 162. This causes slightdeformation of the first and second legs 572, 574 of the inner section504 at their respective kinks 622, 624.

FIG. 21D depicts the section 630 of the first leg 512 bended more towardthe tension web 506 and the section 622 of the second leg 514substantially parallel to the tension web 506. The closedcross-sectional portion 510 begins to partially deform, and the endportions 526, 528 (i.e., the substantially horizontal wall parts of theclosed cross-sectional portion 510) begin to at least partially collapseinto the enclosed space defined by the closed cross-sectional portion510. The wall part 536 bulges toward the side wall 170 of the outerpanel member 160. And the closed cross-sectional portion 510 at leastpartially forces the base member 570 of the inner section 504 toward theside wall 180 of the inner panel member 162. This, in turn, causes eachof the first and second legs 572, 574 to further deform at theirrespective kinks 622, 624 due to the joints defined by the respectiveend portions 576, 578 adhered to the upper and lower corner portions240, 242. As depicted, the first leg 572 begins to fold upward in thevehicle height direction about the kink 622, and the second leg 574 alsobegins to fold upward in the vehicle height direction about the kink 624Further, the continued lateral force applied to the outer panel member160 continues to deform the tension web 506.

FIGS. 21E and 21F depict each of the sections 630, 632 of the respectivefirst and second legs 512, 514 of the outer section 502 folded moretoward the tension web 506. The portions 526, 528, which define thesubstantially horizontal wall parts of the closed cross-sectionalportion 510, are collapsed further toward one another. The tension web506 in the area of the closed cross-sectional portion 510 bulges moretoward the side wall 180 of the inner panel member 162 (see point 05).The continued lateral force applied to the structural member 102 causesthe first leg 572 to fold further upward about the kink 622. A section636 of the second leg 574 folds upward about the kink 624 and a section638 of the second leg laterally inward of the section 636 begins to folddownward about a separate kink or bend 640 (see points 05 and 06). Thisis at least partially due to engagement of the second reinforcing ribs584 with the side wall 180.

As illustrated in FIGS. 21G and 21H, the closed cross-sectional portion510 of the outer section 502 continues to deform from the lateral forceapplied to the structural member 120. The wall part 536 of the closedcross-sectional portion 510 is moved into contact with the side wall 170of the outer panel member 160. And the end portions 576, 578 of thefirst and second legs 572, 574 of the inner section 504 continue to foldalong the side wall 180 of the inner panel member 162 (see points 07 and08). FIG. 211 depicts the first and second legs 572, 574 of the innersection 504 further deformed (see point 09). FIG. 21J depicts a finaldeformed state of the structural member 102 and reinforcement member 500at point 10 on the graph of FIG. 20.

FIG. 22 depicts an exemplary reinforcement member 650 according toanother embodiment of the present disclosure. The reinforcement member650 incudes an outer section 652, an inner section 654, and a tensionweb 656 interposed between and directly contacting the outer section 652and the inner section 654. According to one aspect, the outer section652 is substantially hat-shaped and includes a base member 658 and firstand second legs 660, 662 extending outwardly from the base member 658.Flanges 664, 666 located on end portions 668, 670 of the respectivefirst and second legs 660, 662 have placed thereon the adhesive 246.Similarly, the inner section 654 is also substantially hat-shaped andincludes a base member 680 and first and second legs 682, 684 extendingoutwardly from the base member 680. As depicted, the base member 680 issized greater than the base member 658. Flanges 686, 688 located on endportions 690, 692 of the respective first and second legs 682, 684 haveplaced thereon the adhesive 246. Each of the outer section 502, innersection 504 and tension web 506 can include a first metal or metalalloy, and can be formed of a steel or steel alloy. This allows thecomponents 652, 654, 656 of the exemplary reinforcement member 650 to befixedly attached to one another, such as by welding.

As shown in FIGS. 23 and 24, the reinforcement member 650 is positionedin the cavity 166 of the structural member 102 such that a gap 696 isinitially provided between the reinforcement member 650 and the innersurfaces of the outer and inner panel members 160, 162. As indicatedpreviously, the gap 696 allows for the provision of the anticorrosioncoating on the inner surface of the structural member by an electrocoatprocess. The outer section 652 faces the outer panel member 160 with thefirst and second legs 660, 662 extending toward the inner surface of theouter panel member 160, and the inner section 654 faces the inner panelmember 162 with the first and second legs 682, 684 extending toward theinner surface of the inner panel member 162. The tension web 656 issecured to the outer and inner panel members 160, 162 of the structuralmember 102 by fixedly attaching the tension web 656 to the upper flanges176, 186 and lower flanges 178, 188 of the outer and inner panel members160, 162. The adhesive 246 attaches the flanges 664, 666 to therespective upper and lower corner portions 220, 222 of the outer panelmember 160 and attaches the flanges 686, 688 to the respective upper andlower corner portions 240, 242 of the inner panel member 162.

FIG. 25 graphically depicts an impact or test barrier force versesdisplacement caused by a side impact to the structural member or sidesill 102 having the reinforcement member 650 positioned in the cavity166 of the structural member. FIGS. 26A-26J schematically depict, incross-section, the deformation of the structural member 102 andreinforcement member 650 at selected points on the graph of FIG. 25.Similar to the previous embodiments of the reinforcement member, thefirst and second legs 660, 662 of the outer section 652 and the firstand second legs 682, 684 of the inner section 654 of the exemplaryreinforcement member 650 define a lateral load path from the outer panelmember 160 toward the inner panel member 162 during a side impact to thestructural member 102.

In FIGS. 26A and 26B, initial force from a side impact to the outerpanel member 160 of the structural member 102 causes partial deformationof the side wall 170 and the first and second legs 660, 662 of the outersection 652 (see point 01). The end portions of 668, 670 of the firstand second legs 660, 662 start to fold onto the side wall 170 (see point02). In FIG. 26C, the lateral load continues to fold the first andsecond legs 660, 662 of the outer section 652 at point 03. Further, thebase member 658 of the outer section 652 bulges the tension web 656together with the base member 680 of the inner section 654 toward theside wall 180 of the inner panel member 162 (see point 03). FIG. 26Ddepicts deformation of the base member 680 and the end portion 692 ofthe second leg 684 of the inner section 654 (see point 04).

FIG. 26E depicts at point 05 further deformation of the first and secondlegs 660, 662 of the outer section 652 and the first and second legs682, 684 of the inner section 654. FIG. 26F at point 06 showsdeformation of the connection of the tension web 656 to the flanges 178,188 of the outer and inner panel members 160, 162. FIGS. 26G and 26Hdepict the first and second legs 682, 684 of the inner section 656 beingfolded in a vehicle height direction toward the side wall 180 of theinner panel member 162 (see points 07 and 08). FIG. 26I depicts thefirst and second legs 682, 684 of the inner section 654 further deformedalong the side wall 180 (see point 09). FIG. 26J depicts a finaldeformed state of the structural member 102 and reinforcement member 650at point 10 on the graph of FIG. 25.

For the above embodiments of the reinforcement members 120, 300, 400,500, 650, a vehicle body construction method will now be described. Inthe exemplary method, an elongated structural member 102 having an innersurface and defining an elongated cavity 166 is provided. The structuralmember 102 can be defined by an outer panel member 160 attached to aninner panel member 162. The structural member includes a first metal ormetal alloy, and can be formed of a steel or steel alloy.

Next, a reinforcement member 120, 300, 400, 500, 650 is provided. Thereinforcement member is adapted for insertion in the cavity 166 with agap between the reinforcement member and the inner surface of thestructural member 102. As set forth in detail above, the reinforcementmember 120, 300, 400, 500, 650 comprises an outer section 122, 302, 402,502, 652, an inner section 124, 304, 404, 504, 654 and a tension web126, 306, 406, 506, 656 interposed between the inner and outer sections.The outer section 122, 302, 402, 502 can include a closedcross-sectional portion 130, 310, 410, 510 in direct contact with thetension web and having a side wall part 152, 336, 436, 536 spaced fromand substantially parallel to the tension web 126, 306, 406, 506. Theouter section and the tension web include a second metal or metal alloydifferent than the first metal or metal alloy, and can be formed of analuminum or aluminum alloy. The inner section includes one of the firstmetal or metal alloy, the second metal or metal alloy, a reinforcedpolymer, and a honeycomb structure 480.

Next, an adhesive 246 can be applied onto contact portions of thereinforcement member 120, 300, 400, 500, 650. For example, the adhesivecan be applied to contact portions of both the outer section and innersection of the reinforcement member. Next, the reinforcement member 120,300, 400, 500, 650 can be installed within the structural member 120 toreinforce the structural member. Such installing of the reinforcementmember 120, 300, 400, 500, 650 within the structural member 120 caninclude positioning the reinforcement member within the structuralmember 120 so that a gap is provided between the adhesive 246 and theinner surfaces of the outer panel member 160 and inner panel member 162.This allows anticorrosion fluid to flow between the reinforcement member120, 300, 400, 500, 650 and the inner surface of the structural member102. Next, the method includes subsequently applying heat to theadhesive 246 to expand the adhesive and bond the contact portions of thereinforcement member to the structural member 102.

Applied to the vehicle frame construction, positioning the reinforcementmember 120, 300, 400, 500, 650 within the structural member 102 caninvolve positioning the reinforcement member with the adhesive 246already applied thereon on one of the parts that comprise the structuralmember (e.g., the inner panel member 162) and then the other of theparts that comprise the structural member (e.g., the outer panel member160) can be combined to enclose the reinforcement member. At this stage,the adhesive 246 has not yet had heat applied for heat activationthereof and thus does not fully function to define structural jointsbetween the inner surface of the structural member 102 and the contactportions of the reinforcement member. However, when heat is applied tothe adhesive 246 (e.g., as the vehicle body passes through variousheating apparatus, e.g., ovens, to address surface finishing of thevehicle body), the adhesive 246 expands and bonds the contact portionsof the reinforcement member 120, 300, 400, 500, 650 to the structuralmember 102. At this stage, the reinforcement member is fully installedwithin the structural member 102 and the structural member 102 isreinforced by the reinforcement member.

As is evident from the foregoing embodiments, a method of reinforcing astructural member 102 of a vehicle body is also provided. The structuralmember 102 includes an inner surface defining an elongated cavity 166,and an outer panel member 160 joined to an inner panel member 162. Themethod comprises providing a reinforcement member 120, 300, 400, 500,650 including an outer section 122, 302, 402, 502, 652, an inner section124, 304, 404, 504, 654 and a tension web 126, 306, 406, 506, 656interposed between and directly secured to the outer and inner sections;providing an adhesive 246 on the reinforcement member 120, 300, 400,500, 650; securing the tension web to the structural member 102 so thatthe tension web substantially separates the outer and inner panelmembers 160, 162; providing a gap between the adhesive 246 and the innersurface of the structural member 102 prior to activation of the adhesive246; and activating the adhesive 246 to expand the adhesive outward fromthe reinforcement member into engagement with the inner surface of thestructural member 102.

The outer section 122, 302, 402, 502 of the exemplary reinforcementmember can include a closed cross-sectional portion 130, 310, 410, 510and the method further includes positioning the closed cross-sectionalportion in direct contact with the tension web and securing the innersection at the same location on the tension web as the closedcross-sectional portion. According to one aspect, the closedcross-sectional portion 310, 410, 510 is rectangular shaped, and themethod includes configuring substantially horizontal wall parts of theclosed cross-sectional portion to fold inwardly into the closedcross-sectional portion during a side impact to the outer panel member160 of the structural member 102. According to one aspect, at least oneof the outer section and inner section can include first and second legsextending toward the structural member 102 and the method includesconfiguring a portion each of the first and second legs to fold at leastpartially into the tension web during a side impact to the outer panelmember 160 of the structural member. According to another aspect, theinner section 404 includes a honeycomb structure 480 having a pluralityof opening, and the method includes orienting the opening substantiallynormal to a longitudinal axis of the structural member 102.

FIG. 27 depicts an exemplary reinforcement member 700 according toanother aspect of the present disclosure. The reinforcement member 700includes an outer section 702 and an inner section 704. The outersection 702 of the reinforcement member 700 includes a first closedcross-sectional portion 710 and first and second legs 712, 714 extendingoutwardly from the first closed cross-sectional portion 710. It shouldbe appreciated that the first closed cross-sectional portion 710effectively shortens the first and second legs 712, 714, making thefirst and second legs 712, 714 stiffer in compression. The first closedcross-sectional portion 710 is at least partially defined by respectiveend portions 716, 718 of the first and second legs 712, 714. The endportions 716, 718 define substantially horizontal wall parts of thefirst closed cross-sectional portion 710. The first closedcross-sectional portion 710 is further defined by substantially verticalwall parts 720, 722. The substantially horizontal wall parts 716, 718 ofthe first closed cross-sectional portion 710 are at least partiallycurved toward one another, and are adapted to at least partiallycollapse into an enclosed space 726 defined by the first cross-sectionalportion 710. The outer section 702 of the reinforcement member 700further includes an outer substantially vertically wall part 730interconnecting opposite end portions 732, 734 of the respective firstand second legs 712, 714. The substantially vertically wall part 730includes a centrally located section 740 and curved sections 742, 744provided on opposite ends of the central section 740. The substantiallyvertically wall parts 722, 730 and the end portions 732, 734 define asecond closed cross-sectional portion 750.

The inner section 704 of the exemplary reinforcement member 700 includesfirst and second legs 760, 762. At least one of the first and secondlegs 760, 762 of the inner section 704 has a kink or bend which movesthe one leg slightly toward the other leg. The kink is provided tocontrol deformation of that leg during a side or lateral impact to thestructural member. As depicted, the first leg 760 includes an upwardkink 770 located substantially centrally on the first leg 760, and thesecond leg 762 includes a downward kink 772 located substantiallycentrally on the second leg 762. The inner section 704 further includesa pair of substantially vertical wall parts 776, 778. The substantiallyvertical wall part 776 interconnects end portions 780, 782 of therespective first and second legs 760, 762. And the substantiallyvertical wall part 778 interconnects opposite end portions 784, 786 ofthe respective first and second legs 760, 762. The first and second legs760, 762 together with the substantially vertical wall parts 776, 778define a closed cross-sectional portion 790.

As shown in FIG. 27, when initially positioned in the cavity 166 of thestructural member 102 a gap is provided between the reinforcement member700 and the inner surfaces of the outer and inner panel members 160, 162which allows for the provision of the anticorrosion coating on the innersurface of the structural member 102 by an electrocoat process. Theouter section 702 faces the outer panel member 160 with the first andsecond legs 712, 714 extending toward the inner surface of the outerpanel member 160, and the inner section 704 faces the inner panel member162 with the first and second legs 762, 764 extending toward the innersurface of the inner panel member 162. The end portions 732, 734 of therespective first and second legs 712, 714 of the outer section 702 areprovided with flanges 796, 798 shaped to conform to respective upper andlower corner portions 220, 222 of the outer panel member 160. Asdepicted, the flange 796 is at least partially defined by a closedcross-sectional portion or lobe 800. Similarly, end portions 784, 786 ofthe respective first and second legs 760, 762 of the inner section 704are provided with flanges 804, 806 shaped to conform to respective upperand lower corner portions 240, 242 of the inner panel member 162. Asdepicted, the flange 804 is at least partially defined by a closedcross-sectional portion or lobe 810. The lobes 800, 810 enhance bendperformance of the reinforcement member 700.

To secure the reinforcement member 700 with the cavity 166 of thestructural member 102, the substantially vertical wall parts 720, 776 ofthe respective outer and inner sections 702, 704 are secured to atension web 820. As shown in FIGS. 28 and 29, the tension web 820includes an upper portion 822 and a lower portion 824. A plurality offormations 826, 828 (e.g., depressions or cavities) are provided on thetension web 820. The formations 826 are of a first shape (e.g., atriangular shape) and protrude from a first surface 830 of the tensionweb. The formations 828 are of a second shape (e.g., a rectangularshape) and protrude from a second opposite surface 830 of the tensionweb 820. According to one aspect, the formations 826 are separated fromone another by the formations 828. As indicated previously, thestructural member 102 includes a first metal or a metal alloy, and canbe formed of a steel or steel alloy. The tension member 820 can also beformed of the first metal or metal alloy allowing the upper and lowerportions 822, 824 to be directly connected to the respective upperflanges 176, 186 and the lower flanges 178, 188 of the outer and innerpanel members 160, 162. The outer and inner sections 702, 704 of thereinforcement member 700 are formed of a second metal or metal alloydifferent from the first metal or metal alloy (e.g., an aluminum oraluminum alloy). This allows the outer and inner sections 702, 704 to beintegrally formed as a one-piece, unitary member, such as by anextrusion process.

The substantially vertical wall part 720 of the outer section 702 isadhered to the tension web 820 and the substantially vertical wall part776 of the inner section 704 is fastened to the tension web 820 (e.g.,by use of a self-piercing rivet). Similarly, the central section 740 ofthe substantially vertical wall part 730 of the outer section 702 issecured to the side wall 170 of the outer panel member 160 (e.g., by useof a self-piercing rivet). Because of the differing materials anadhesive/insulator can be placed between the tension web 820 and thewall part 720 and between the side wall 170 and the wall part 730 toprevent galvanic corrosion. The adhesive 246 is secured to each of theflanges 796, 798 of the outer section 702 and each of the flanges 804,806 of the inner section 704.

FIGS. 30-36 depict an exemplary reinforcement member 850 according toanother aspect of the present disclosure. The reinforcement member 850includes an outer section 852, an inner section 854, and the tension web820 interposed between the outer and inner sections 852, 854. The outersection 852 of the reinforcement member 850 includes substantiallyhorizontal wall parts (i.e., first and second legs) 860, 862 andsubstantially vertical wall parts 864, 866. The wall parts 860-866 ofthe outer section 852 define a closed cross-sectional portion 870 havingan enclosed space 872. In the depicted embodiment, each of the first andsecond legs 860, 862 can be arcuate shaped, curved away from theenclosed space 872 (i.e., the first and second legs 860, 862 curvedtoward the respective top and bottom walls 172, 174 of the outer panelmember 160). With this configuration, the first and second legs 860, 862are adapted to at least partially collapse toward the respective top andbottom walls 172, 174 during a side/lateral impact to the structuralmember 102. The substantially vertical wall part 864 interconnects endportions 880, 882 of the respective first and second legs 860, 862, andthe substantially vertical wall part 866 interconnects opposite endportions 886, 888 of the respective first and second legs 860, 862. Theend portions 880, 882 of the respective first and second legs 860, 862can be provided with flanges 890, 892 which are substantially alignedwith the substantially vertical wall part 864, thereby definingextensions of the substantially vertical wall part 864. Further, the endportions 886, 888 of the respective first and second legs 860, 862include flanges 896, 898 shaped to conform to respective upper and lowercorner portions 220, 222 of the outer panel member 160. As depicted,each of the flanges 896, 898 is spaced from respective end portions ofthe substantially vertical wall part 866. The flange 896 can be at leastpartially defined by a closed cross-sectional portion or lobe 900 andthe flange 898 can be substantially parallel to the substantiallyvertical wall part 866.

The inner section 854 of the exemplary reinforcement member 850 includessubstantially horizontal wall parts (i.e., first and second legs) 910,912 and substantially vertical wall parts 914, 916. Similar to the outersection 852, the wall parts 910-916 of the inner section 854 define aclosed cross-sectional portion 920 having an enclosed space 922. In thedepicted embodiment, each of the first and second legs 910, 912 can bearcuate shaped, curved toward the respective top and bottom walls 182,184 of the inner panel member 162. With this configuration, the firstand second legs 910, 912 are adapted to at least partially collapsetoward the respective top and bottom walls 182, 184 during aside/lateral impact to the structural member 102. The substantiallyvertical wall part 914 interconnects end portions 930, 932 of therespective first and second legs 910, 912, and the substantiallyvertical wall part 916 interconnects opposite end portions 936, 938 ofthe respective first and second legs. The end portions 930, 932 of therespective first and second legs 910, 912 can be provided with flanges940, 942 which are substantially aligned with the substantially verticalwall part 914, thereby defining extensions of the substantially verticalwall part 914. Further, the end portions 936, 938 of the respectivefirst and second legs 910, 912 include flanges 946, 948 shaped toconform to respective upper and lower corner portions 240, 242 of theinner panel member 162. As depicted, the flange 946 can be at leastpartially defined by a closed cross-sectional portion or lobe 950, andeach of the flanges 946, 948 extends laterally outwardly past thesubstantially vertical wall part 916. The lobes 900, 950 enhance bendperformance of the reinforcement member 850.

As shown in FIG. 36, the reinforcement member 850 is positioned in thecavity 166 of the structural member 102 wherein a gap 954 is providedbetween the reinforcement member 850 and the inner surfaces of the outerand inner panel members 160, 162. Again, the gap 954 allows for theprovision of the anticorrosion coating on the inner surface of thestructural member by an electrocoat process. The outer section 852 facesthe outer panel member 160 with the first and second legs 860, 862extending toward the inner surface of the outer panel member 160, andthe inner section 854 faces the inner panel member 162 with the firstand second legs 910, 912 extending toward the inner surface of the innerpanel member 162.

To secure the reinforcement member 850 with the cavity 166 of thestructural member 102, the substantially vertical wall parts 864, 914 ofthe respective outer and inner sections 852, 854 are adhered to thetension web 820. Similarly, the substantially vertical wall part 866 ofthe outer section 852 is adhered to the side wall 170 of the outer panelmember 160. It should be appreciated that each of the substantiallyvertical wall parts 864, 914 can be fastened to the tension web 820 andthe substantially vertical wall part 866 can be fastened to the sidewall 170 (e.g., by use of self-piercing rivets). Again, the structuralmember 102 and the tension member 820 includes a first metal or a metalalloy, and can be formed of a steel or steel alloy. The outer and innersections 852, 854 are formed of a second metal or metal alloy differentfrom the first metal or metal alloy (e.g., an aluminum or aluminumalloy), which allows the outer and inner sections 852, 854 to beintegrally formed as a one-piece, unitary member, such as by anextrusion process. Because of the differing materials anadhesive/insulator can be placed between the tension web 820 and thewall parts 864, 914 and between the side wall 170 and the wall part 866to prevent galvanic corrosion. The adhesive 246 is secured to each ofthe flanges 896, 898 of the outer section 852 and each of the flanges946, 948 of the inner section 854.

FIGS. 37-41 depict an exemplary reinforcement member 1000 according toanother aspect of the present disclosure. The reinforcement member 1000includes the outer section 852, an inner section 1004, and the tensionweb 820 interposed between the outer and inner sections 852, 1004. Theinner section 1004 includes a base member 1010 including a plurality ofprojections or bumpers extending laterally therefrom. In the illustratedembodiment, the plurality of projections includes an array of spacedfirst projections or bumpers 1012 and an array of spaced secondprojections or bumpers 1014 provided below the first bumpers 1012. Asshown, each of the first and second bumpers 1012, 1014 can be elongated(in a lateral direction) polygonal shaped members. Further, each of thefirst bumpers 1012 can have a shape differing from a shape of aneighboring (e.g., adjacent) first bumper 1012, and each of the secondbumpers 1014 can have a shape differing from a shape of a neighboring(e.g., adjacent) second bumper 1014. And each first bumper 1012 can havea shape differing from a shape of the second bumper 1014 located belowthat first bumper. Although, it should be appreciated that at least someof the first and second bumpers 1012, 1014 can be similarly shaped.Still further, each of the first and second bumpers 1012, 1014 can beadapted to tune or control deformation and bending of the inner section1004 during a side impact to the structural member 102. The base member1010 also includes a first flange 1020 and a second flange 1022, andeach of the first and second flanges can extend continuously withoutinterruption along the longitudinal extent of the base member 1010. Thefirst bumpers 1012 are interconnected by the first flange 1020, and thesecond bumpers 1014 are interconnected by the second flange 1022. Adistal end portion 1026 of the first flange 1020 has a shapecomplimentary to the upper corner portion 240 of the inner panel member162. And a distal end portion 1028 of the second flange 1022 has a shapecomplimentary to the lower corner portion 242 of the inner panel member162.

According to one aspect, a plurality of spaced apart first reinforcingribs (i.e., gussets) 1030 can be provided between the first flange 1020and the first bumpers 1012, and a plurality of spaced apart secondreinforcing ribs (i.e. gussets) 1032 can be provided between the secondflange 1022 and the second bumpers 1014. It should be appreciated thatthe first and second reinforcing ribs 1030, 1032 can define incross-section respective kink or bends 1036, 1038 adapted to furthercontrol deformation and bending of the inner section 1004 to preventbreakage of the inner section 1004 during a side impact to thestructural member 102. In the depicted embodiment, a plurality of thirdreinforcing ribs 1040 can extend between the first and second flanges1020, 1022, thereby interconnecting the first and second bumpers 1012,1014. Each of the third reinforcing ribs 1040 can be generally X orH-shaped, and as shown the third reinforcing ribs 1040 are generallyH-shaped including a first segment 1042, a second segment 1044 and athird segment 1046 connecting the first and second segments. Each of thefirst and second segments 1042, 1044 can be curved toward one anotherand an opening can be provided in the third segment 1046 for weightreduction.

The inner section 1004 of the exemplary reinforcement member 1000 is aone-piece, unitary member formed of a reinforced polymer. In oneembodiment, the inner section 1004 is formed from a fiber reinforcedplastic including a plastic matrix material that encapsulates a fibermaterial. For example, the plastic matrix material can be nylon and/orthe fiber material can be a plurality of glass fibers, which providespreferred structural characteristics while maintaining a reasonableweight for the inner section 1004.

As shown in FIG. 41, the reinforcement member 1000 is initiallypositioned in the structural member 102 such that a gap 1048 is providedbetween the reinforcement member 1000 and the inner surfaces of theouter and inner panel members 160, 162. Again, the gap 1048 allows forthe provision of the anticorrosion coating on the inner surface of thestructural member by an electrocoat process. The outer section 852 issecured within the structural member 102 in the same manner describedabove. The inner section 1004 is positioned within the structural member102 with the first and second flanges 1020, 1022 facing the inner panelmember 162. The base member 1010 (particularly each of the first andsecond bumpers 1012, 1014) can be adhered to the tension web 820 viaadhesive and/or selective first and second bumpers can be attached tothe tension web 820 by conventional fasteners, such as clips or rivets.The adhesive 246 is provided on the distal end portions 1026, 1028 ofthe respective first and second flanges 1020, 1022, which attaches thedistal end portions to the respective upper and lower corner portions240, 242 of the inner panel member 162.

FIGS. 42-46 depict an exemplary reinforcement member 1050 according toyet another aspect of the present disclosure. The reinforcement member1050 includes an outer section 1052, the inner section 854, and thetension web 820 interposed between the outer and inner sections 1052,854. The outer section 1052 includes a base member 1054 having aplurality of projections or bumpers extending laterally therefrom.According to one aspect, the plurality of projections includes an arrayof spaced first projections or bumpers 1056 and an array of spacedsecond projections or bumpers 1058 provided below the first bumpers1056. Each of the first bumpers 1056 can be elongated (in a lateraldirection) polygonal shaped members, and in the depicted embodimentsidewalls 1062, 1064 of the first bumpers 1056 can be generallytriangular shaped, allowing the side walls to serve as reinforcinggussets for the first bumpers 1052. Still further, as shown thesidewalls 1062, 1064 together with upper walls 1066 of the first bumpers1056 can converging toward one another adjacent the base member 1054,and with this arrangement an upper part of each of the first bumpers1056 can be generally tent-shaped. The second bumpers 1058 can also beelongated polygonal shaped members, and in the depicted embodiment areshaped similar to the first bumpers 1056. Although, it should beappreciated that selected of the first and second bumpers 1056, 1058 canhave differing shapes allowing each of the first and second bumpers totune or control deformation and bending of the outer section 1052 duringa side impact to the structural member 102. Upper and lowerlongitudinally extending reinforcing ribs 1070, 1072 are provided on thebase member 1054, the upper reinforcing rib 1070 interconnecting thefirst bumpers 1056 and the lower reinforcing rib 1072 interconnectingthe second bumpers 1058. According to one aspect, the base member 1054can further include at least one longitudinally extending thirdreinforcing rib 1074 located between the upper and lower ribs 1070,1072, and in the illustrated embodiment, a pair of third reinforcingribs 1074 is provided on the base member 1054. Further, a plurality offourth reinforcing ribs 1076 can be provided on the base member 1054,the fourth reinforcing ribs extending between and interconnecting thefirst and second bumpers 1056, 1058. A distal end portion of each of thefirst bumpers 1056 can have a shape complimentary to the upper cornerportion 220 of the outer panel member 160, and a distal end portion ofeach second bumper 1058 can have a shape complimentary to the lowercorner portion 222 of the outer panel member 160.

Similar to the inner section 1004 of the reinforcement member 1000, theouter section 1052 of the exemplary reinforcement member 1050 is aone-piece, unitary member formed of a reinforced polymer. In oneembodiment, the outer section 1052 is formed from a fiber reinforcedplastic including a plastic matrix material that encapsulates a fibermaterial. For example, the plastic matrix material can be nylon and/orthe fiber material can be a plurality of glass fibers, which providespreferred structural characteristics while maintaining a reasonableweight for the outer section 1052.

As shown in FIG. 46, the reinforcement member 1050 is initiallypositioned in the structural member 102 such that a gap 1080 is providedbetween the reinforcement member 1050 and the inner surfaces of theouter and inner panel members 160, 162. Like the previous embodiments,the gap 1080 allows for the provision of the anticorrosion coating onthe inner surface of the structural member by an electrocoat process.The outer section 1052 is positioned within the structural member 102with the first and second bumpers 1056, 1058 facing the sidewall 170 ofthe outer panel member 160. The base member 1054, particularly thereinforcing ribs 1070, 1072, 1074 of the base member 1054, can beadhered to the tension web 820 via adhesive and/or attached to thetension web 820 by conventional fasteners, such as clips or rivets. Theadhesive 246 is provided on the distal end portions of the respectivefirst and second bumpers 1056, 1058, which attaches the distal endportions to the respective upper and lower corner portions 220, 222 ofthe outer panel member 160. The inner section 854 is secured within thestructural member 102 in the same manner described above.

FIGS. 47-49 depict an exemplary reinforcement member 1100 according toyet another aspect of the present disclosure. The reinforcement member1100 includes the outer section 1052, the inner section 1004, and thetension web 820 interposed between the outer and inner sections 1052,1004. Because the structural components of the reinforcement member 1110were described above, further description of the reinforcement member1100 will be omitted for conciseness.

FIGS. 50 and 51 depict an exemplary reinforcement member 1120 accordingto still yet another aspect of the present disclosure. The reinforcementmember 1120 includes the outer section 852, the inner section 404, andthe tension web 820 interposed between the outer and inner sections1052, 1004. Because the structural components of the reinforcementmember 1120 were described above, further description of thereinforcement member 1120 will be omitted for conciseness.

FIGS. 52 and 53 depict an exemplary reinforcement member 1140 accordingto still yet another aspect of the present disclosure. The reinforcementmember 1140 includes the outer section 1052, the inner section 404, andthe tension web 820 interposed between the outer and inner sections1052, 1004. Again, because the structural components of thereinforcement member 1140 were described above, further description ofthe reinforcement member 1140 will be omitted for conciseness.

FIGS. 54-58 depict an exemplary reinforcement member 1150 according tostill yet another aspect of the present disclosure. The reinforcementmember 1150 includes the outer section 852, an inner section 1154, andthe tension web 820 interposed between the outer and inner sections 852,1154. The inner section 1154 of the reinforcement member 1150 includes agenerally hat-shaped section 1158 defined by first and second legs 1160,1162 extending outwardly (in a lateral direction) from a substantiallyvertical base member 1164 (which is in contact with the tension web820). A separate cover member 1168 is secured to end portions 1170, 1172of the respective first and second legs 1160, 1162, the cover member1168 defining a substantially vertical wall part of the inner section1154. The cover member 1168 can be provided with cutouts 1174 to reducethe weight of the inner section 1154. End portions 1180, 1182 of thecover member 1168 are shaped to conform to the respective upper andlower corner portions 240, 242 of the inner panel member 162. Each ofthe first and second legs 1160, 1162 and the base member 1164 caninclude respective strengthening ribs 1186, 1188, 1190. Further, atleast one of the first and second legs 1160, 1162 of the inner sectionhas a kink or bend which moves the one leg slightly toward the other legduring a side or lateral impact to the structural member 102, therebyproviding a controlled deformation of that leg during impact. Asdepicted, the first leg 1160 includes an upward kink 1194 locatedsubstantially centrally on the first leg 1160, and the second leg 1162includes a downward kink 1196 located substantially centrally on thesecond leg 762. The inner section 1154 can be formed of the same orsimilar first metal or metal alloy as the structural member 102 and thetension web 820.

As shown in FIG. 58, the reinforcement member 1150 is initiallypositioned in the structural member 102 such that a gap 1198 is providedbetween the reinforcement member 1150 and the inner surfaces of theouter and inner panel members 160, 162. Like the previous embodiments,the gap 1198 allows for the provision of the anticorrosion coating onthe inner surface of the structural member by an electrocoat process.The outer section 852 is secured within the structural member 102 in thesame manner described above. The inner section 1154 is positioned withinthe structural member 102 with the first and second legs 1160, 1162extending toward the sidewall 180 of the inner panel member 162 and thecover member 1168 spaced from and facing the sidewall 180. The basemember 1164 can be attached to the tension web 820 by conventionalfasteners, such as self-piercing rivets, and, if needed, anadhesive/insulator can be placed between the tension web 820 and basemember 1164 to prevent galvanic corrosion. The adhesive 246 is providedon the end portions 1180, 1182 of the cover member 1168, which attachesthe inner section 1150 to the inner panel member 162.

FIGS. 59-61 depict an exemplary reinforcement member 1200 according tostill yet another aspect of the present disclosure. The reinforcementmember 1200 includes the outer section 1052, the inner section 1154, andthe tension web 820 interposed between the outer and inner sections1052, 1004. Because the structural components of the reinforcementmember 1200 were described above, further description of thereinforcement member 1200 will be omitted for conciseness.

For the above embodiments of the reinforcement members 700, 850, 1000,1050, 1100, 1120, 1140, 1150, 1200, a vehicle body construction methodwill now be described. In the exemplary method, an elongated structuralmember 102 having an inner surface and defining an elongated cavity 166is provided. The structural member 102 can be defined by an outer panelmember 160 attached to an inner panel member 162. The structural member102 and the tension web 820 each includes a first metal or metal alloy,and can be formed of a steel or steel alloy.

Next, a reinforcement member 700, 850, 1000, 1050, 1100, 1120, 1140,1150, 1200 is provided. The reinforcement member is adapted forinsertion in the cavity 166 with a gap between the reinforcement memberand the inner surface of the structural member 102. As set forth indetail above, the reinforcement member 700, 850, 1000, 1050, 1100, 1120,1140, 1150, 1200 comprises an outer section 702, 852, 1052, an innersection 704, 854, 1004, 1154 and a tension web 820 interposed betweenthe inner and outer sections. The outer section includes one of a secondmetal or metal alloy different than the first metal or metal alloy, andcan be formed of an aluminum or aluminum alloy, and a reinforcedpolymer. The inner section includes one of the first metal or metalalloy, the second metal or metal alloy, a reinforced polymer, and ahoneycomb structure.

Next, an adhesive 246 can be applied onto contact portions of thereinforcement member 700, 850, 1000, 1050, 1100, 1120, 1140, 1150, 1200.For example, the adhesive can be applied to contact portions of both theouter section and inner section of the reinforcement member. Next, thereinforcement member 700, 850, 1000, 1050, 1100, 1120, 1140, 1150, 1200can be installed within the structural member 120 to reinforce thestructural member. Such installing of the reinforcement member withinthe structural member can include positioning the reinforcement member700, 850, 1000, 1050, 1100, 1120, 1140, 1150, 1200 within the structuralmember 120 so that a gap is provided between the adhesive 246 and theinner surfaces of the outer panel member 160 and inner panel member 162.This allows anticorrosion fluid to flow between the reinforcement memberand the inner surface of the structural member. Next, the methodincludes subsequently applying heat to the adhesive 246 to expand theadhesive and bond the contact portions of the reinforcement member 700,850, 1000, 1050, 1100, 1120, 1140, 1150, 1200 to the structural member102.

Applied to the vehicle frame construction, positioning the reinforcementmember 700, 850, 1000, 1050, 1100, 1120, 1140, 1150, 1200 within thestructural member 102 can involve positioning the reinforcement memberwith the adhesive 246 already applied thereon on one of the parts thatcomprise the structural member (e.g., the inner panel member 162) andthen the other of the parts that comprise the structural member (e.g.,the outer panel member 160) can be combined to enclose the reinforcementmember. At this stage, the adhesive 246 has not yet had heat applied forheat activation thereof and thus does not fully function to definestructural joints between the inner surface of the structural member 102and the contact portions of the reinforcement member. However, when heatis applied to the adhesive 246 (e.g., as the vehicle body passes throughvarious heating apparatus, e.g., ovens, to address surface finishing ofthe vehicle body), the adhesive 246 expands and bonds the contactportions of the reinforcement member 700, 850, 1000, 1050, 1100, 1120,1140, 1150, 1200 to the structural member 102. At this stage, thereinforcement member is fully installed within the structural member 102and the structural member 102 is reinforced by the reinforcement member.

As is evident from the foregoing embodiments, a method of reinforcing astructural member 102 of a vehicle body is also provided. The structuralmember 102 includes an inner surface defining an elongated cavity 166,and an outer panel member 160 joined to an inner panel member 162. Themethod comprises providing a reinforcement member 700, 850, 1000, 1050,1100, 1120, 1140, 1150, 1200 including 702, 852, 1052, an inner section704, 854, 1004, 1154 and a tension web 820 interposed between anddirectly secured to the outer and inner sections; providing an adhesive246 on the reinforcement member 700, 850, 1000, 1050, 1100, 1120, 1140,1150, 1200; securing the tension web to the structural member 102 sothat the tension web substantially separates the outer and inner panelmembers 160, 162; providing a gap between the adhesive 246 and the innersurface of the structural member 102 prior to activation of the adhesive246; and activating the adhesive 246 to expand the adhesive outward fromthe reinforcement member into engagement with the inner surface of thestructural member 102.

The exemplary method further includes securing the projections 1056,1058 of the outer section 1052 to the inner surface of the structuralmember 102 and securing the base member 1054 of the outer section 1052to the tension web 820. And the exemplary method further includessecuring the projections 1012, 1014 of the inner section 1004 to thetension web 820 and securing the base member 1010 of the inner section1004 to the inner surface of the structural member 102.

It will be appreciated that the above-disclosed and other features andfunctions, or alternatives thereof, may be desirably combined into manyother different systems or applications. Also that various presentlyunforeseen or unanticipated alternatives, modifications, variations orimprovements therein may be subsequently made by those skilled in theart which are also intended to be encompassed by the following claims.

What is claimed is:
 1. A vehicle body comprising: a structural memberhaving an inner surface defining an elongated cavity, the structuralmember including an outer panel member joined to an inner panel member;a reinforcement member positioned in the cavity of the structural memberwherein a gap is provided between the reinforcement member and the innersurface of the structural member, the reinforcement member including: anouter section facing the outer panel member and having a first closedcross-sectional portion, a separate inner section facing the inner panelmember and having a second closed cross-sectional portion, and a tensionweb interposed between and contacting the outer section and innersection, the tension web being secured to the outer panel member andinner panel member; and an adhesive secured to the reinforcement member,the adhesive is activatable to expand toward the inner surface of thestructural member to define a joint between the reinforcement member andthe structural member and to at least partially fill the gap.
 2. Thevehicle body of claim 1, wherein the outer section of the reinforcementmember includes first and second laterally extending legs and third andfourth vertically extending legs, the first and second legsinterconnected by the third and fourth legs to define the first closedcross-sectional portion, the third leg secured to the tension web, thefourth leg secured to the outer panel member.
 3. The vehicle body ofclaim 2, each of the first and second legs of the outer section isarcuate shaped, curved away from the first closed cross-sectionalportion, the first and second legs adapted to at least partiallycollapse toward respective top and bottom walls of the outer panelmember during a side impact to the structural member.
 4. The vehiclebody of claim 2, wherein end portions of the first and second legs ofthe outer section are shaped to conform to respective upper and lowercorner portions of the outer panel member, and the end portion of atleast one of the first and second legs of the outer section includes afirst lobe.
 5. The vehicle body of claim 1, wherein the inner section ofthe reinforcement member includes first and second laterally extendinglegs and third and fourth vertically extending legs, the first andsecond legs interconnected by the third and fourth legs to define thesecond closed cross-sectional portion, the third leg secured to thetension web, the fourth leg spaced from the inner panel member.
 6. Thevehicle body of claim 5, each of the first and second legs of the innersection is arcuate shaped, curved away from the second closedcross-sectional portion, the first and second legs adapted to at leastpartially collapse toward respective top and bottom walls of the innerpanel member during a side impact to the structural member.
 7. Thevehicle body of claim 5, wherein end portions of the first and secondlegs of the inner section are shaped to conform to respective upper andlower corner portions of the inner panel member, and the end portion ofat least one of the first and second legs of the inner section includesa second lobe.
 8. The vehicle body of claim 1, wherein each of the outerpanel member and inner panel member of the structural member ishat-shaped in cross-section and includes upper and lower weld flanges,the upper and lower flanges of the outer member being fixedly attachedto the respective upper and lower flanges of the inner panel member,wherein an upper portion of the tension web is secured to the upperflanges of the outer and inner panel members and a lower portion of thetension web is secured to the lower flanges of the outer and inner panelmembers.
 9. The vehicle body of claim 8, wherein the structural memberincludes a first metal or metal alloy, and each of the outer section andinner section of the reinforcement member includes a second metal ormetal alloy different from the first metal or metal alloy.
 10. Thevehicle body of claim 9, wherein the tension web is formed of the firstmetal or metal alloy, and an insulating material is placed between thetension web and the respective outer and inner sections to preventgalvanic corrosion.
 11. A vehicle body comprising: a structural memberhaving an inner surface defining an elongated cavity, the structuralmember including an outer panel member joined to an inner panel member;a reinforcement member positioned in the cavity of the structural memberwherein a gap is provided between the reinforcement member and the innersurface of the structural member, the reinforcement member including: anouter section facing the outer panel member, a separate inner sectionfacing the inner panel member, the inner section includes a base memberhaving a plurality of bumpers extending laterally therefrom, and atension web interposed between and contacting the outer section andinner section, the tension web being secured to the outer panel memberand inner panel member; and an adhesive secured to the reinforcementmember, the adhesive is activatable to expand toward the inner surfaceof the structural member to define a joint between the reinforcementmember and the structural member and to at least partially fill the gap.12. The vehicle body of claim 11, wherein the outer section of thereinforcement member includes first and second laterally extending legsand third and fourth vertically extending legs, the first and secondlegs interconnected by the third and fourth legs to define a closedcross-sectional portion, the third leg secured to the tension web, thefourth leg secured to the outer panel member.
 13. The vehicle body ofclaim 12, each of the first and second legs of the outer section isarcuate shaped, curved away from the closed cross-sectional portion, thefirst and second legs adapted to at least partially collapse towardrespective top and bottom walls of the outer panel member during a sideimpact to the structural member.
 14. The vehicle body of claim 11,wherein the plurality of bumpers of the inner section of thereinforcement member includes an array of spaced first bumpers and anarray of spaced second bumpers provided below the first bumpers, thefirst and second bumpers are adapted to tune or control deformation andbending of the inner section during a side impact to the structuralmember.
 15. The vehicle body of claim 14, wherein the base memberincludes a first flange adapted to interconnect the first bumpers and asecond flange adapted to interconnect the first bumpers, distal endportions of the first and second flanges shaped to conform to respectiveupper and lower corner portions of the inner panel member.
 16. A vehiclebody comprising: a structural member having an inner surface defining anelongated cavity, the structural member including an outer panel memberjoined to an inner panel member; a reinforcement member positioned inthe cavity of the structural member wherein a gap is provided betweenthe reinforcement member and the inner surface of the structural member,the reinforcement member including: an outer section facing the outerpanel member, the outer section includes a base member having aplurality of bumpers extending laterally therefrom, a separate innersection facing the inner panel member, and a tension web interposedbetween and contacting the outer section and inner section, the tensionweb being secured to the outer panel member and inner panel member; andan adhesive secured to the reinforcement member, the adhesive isactivatable to expand toward the inner surface of the structural memberto define a joint between the reinforcement member and the structuralmember and to at least partially fill the gap.
 17. The vehicle body ofclaim 16, wherein the plurality of bumpers of the outer section of thereinforcement member includes an array of spaced first bumpers and anarray of spaced second bumpers provided below the first bumpers, thefirst and second bumpers are adapted to tune or control deformation andbending of the outer section during a side impact to the structuralmember.
 18. The vehicle body of claim 17, wherein distal end portion ofeach of the first bumpers is shaped to conform to an upper cornerportion of the outer panel member, and a distal end portion of eachsecond bumper is shaped to conform to a lower corner portion of theouter panel member.
 19. The vehicle body of claim 16, wherein the innersection of the reinforcement member includes first and second laterallyextending legs and third and fourth vertically extending legs, the firstand second legs interconnected by the third and fourth legs to define aclosed cross-sectional portion, the third leg secured to the tensionweb, the fourth leg spaced from the inner panel member.
 20. The vehiclebody of claim 19, each of the first and second legs of the inner sectionis arcuate shaped, curved away from the closed cross-sectional portion,the first and second legs adapted to at least partially collapse towardrespective top and bottom walls of the inner panel member during a sideimpact to the structural member.